Painting smarter with AI: how artificial intelligence is changing the paint shop

1. From reactive to predictive maintenance

In traditional production environments, maintenance is often scheduled at fixed times or carried out only when a problem occurs. With AI-assisted maintenance changes that completely.

AI algorithms constantly analyse data from your installations - such as temperature, pressure, vibration or flow rate - and predict when parts are wearing out or deviating from the norm. This allows you to:

• downtime prevented,

• Schedule maintenance at the right time,

• and avoid costly repairs.

At TLCA, we help you integrate the right sensors and data processing into your existing systems to get real insight into your plant condition.

2. Always the right layer thickness: process optimisation in real time

Every paint application must meet specific requirements in terms of coverage, adhesion and finish. But the ideal settings depend on many variables: temperature, humidity, viscosity, substrate, environment...

AI enables those parameters real-time monitoring and adjustment. Continuous analysis of process data allows the system to automatically adjust spray pressure, speed or nozzle control - without operator intervention.

Meaning:
✔ less waste,
✔ a more consistent quality,
✔ and less rejection or rework.

3. Smart quality control without human error

Traditional quality control is time-consuming and subjective. With AI and vision technology, this is changing.

Camera systems with built-in AI algorithms recognise discrepancies in coatings faster than the human eye - from areas that are too thin to dust inclusions or colour differences. And more importantly, the system learns.

So not only do you get error messages, but also insight into recurring patterns as well as suggestions to adjust your process.

4. Controlling energy consumption with smart control

In many paint lines, booths, ventilation or peripheral equipment run on fixed time slots, regardless of effective production. AI makes a big difference here:

• systems are dynamically controlled Based on current occupancy,

• heating cycles are optimised,

• ventilation adapts to the current vapour concentration.

This results in a substantially lower energy consumption, without compromising on safety or quality.

TLCA helps you towards smart lacquer application

As a specialist in industrial paint applications, TLCA helps you get your processes ready for the future too. That means:

• advice on sensor and data selection,

• Guidance on interfacing with existing systems,

• as well as practical support for integration, training and follow-up.

We work with brands like Dürr, which are already applying AI solutions in real production environments.